Plumbing fixture and method of manufacturing the same

ABSTRACT

A BATH TUB OR SIMILAR PLUMBING FIXTURE CONSISTING OF A POLYMETHACRYLATE LINER AND AN OUTER COATING OF GLASSFIBER REINFORCED CURED POLYESTER RESIN IS PRODUCED BY DEEP DRAWING POLYMETHACRYLATE SHEETING INTO THE SHAPE OF THE LINER, SPRAYING A COATING OF POLYESTER RESIN ON THE OUTER   SURFACE OF THE DEEP-DRAWN BODY, EMBEDDING GLASS FIBER FABRIC IN THE SPRAYED COATING, AND CURING THE COATING.

R. WIMMER y Re. 27,430

PLUMBING FIXTURE AND METHoD'oF MANUFACTURING THE SAME July 11; 1972 original Filed sept. `e.` .1964

Flo.:

i liber reinforced cured rate is desired. It is an object of the invention to accelerate the manufacture of wash-basins, bath-tubs, shower traysor 7, 1 970, Seri No. 62,095' Claims priority, application Austria, Sept. 6, 1963,

- A 7,179/63 Int- Cl. B651] /14 U.S. Cl. 220-64 13 Claims Matter enclosed in heavy brackets [1 appears in the original patent but forms no part of ihisrelssiie specifi- Icladoen'gymeatthereprinted in italics indicates the additions ABSTRACT OF THE DISCLOSURE A bath tub or similar- A plumbing fixture consisting of a polymethacrylate liner and an outer coating of 'glass-- polyester resin is produced by deep drawing polyinethacrylate sheeting into the shape of the liner, spraying a coating of polyester resin on the outer surface of the deep-drawn body, embedding glass ber fabric in the sprayed coating, and curing vthe coating This invention relates to plastic plumbing fixtures and to aprocess of manufacturing the same.l J Wash-basins, bath-tubs, shower trays and similar plumbing fixtures are made in most cases of sheet metal,

1964. Application for reissue Aug.

United States Patent Ov trapped between the coating and the --accompanying drawings, in which f Re. 27,430 Reiseued July 11, 1972 -glass fabric is squeezed out by means of rollers.

An vembodiment ofthe invention is shown in the FIG. 1 is a perspective longitudinal sectional view of a base layer .for a bath-tub, FIG. 2 is a view similar to FIG. l of the bathtub. y Y

The exposed inner or lining layer 1 shown in FIG. l is shaped in the form of a bath-tub by vacuum deep drawr ing vfrom polymethacrylate sheeting. After being removed from the vacuum deep drawing apparatus,'it is spraywhich may be enamelled. AIt is also known to ma'kevbath, tubs and the like from polyester resin, which is neinforcedwith glass fibers. The tubs or tublike articles were manufactured theretofore by 'applying one-or more layers of thezunsaturatedpolyester resin, and glass fiber material to -a male mold, and curing the applied material, Because a'certain minimum time is required for curing and the structure cannot be removed from the mold before it is cured, the process takes a relatively longtime, and many molds must be available when a higher production the ilike fromplastics and consequently to reduce their cost. t

' The process according to the invention resides in suitax of -polymethacrylic ester.

bly' shaping a hollow body from sheetingof thermoplastic Y synthetic material, such as polymetha'crylate, preferably by vacuum deep-drawing, and coating'theoutensurface of the hollow body ina known manner with a thermo-l setting synthetic material, preferably an unsaturated polyester resin reinforced with glass libersThehollow bodiescan be made in a quick and simple manner by deep*drawingfAthermoplastic ,hollow body, however,

is no t suitable for use as a plumbingy fixture because washbasins and the like must withstand elevated temperatures.

The vsubsequently `ap'plied'outer .coating of polyester or other thermosetting resin when cured provides strong support at elevated temperature to the thermoplastic synthetic body or liner which replaces the' previously required molds.rHence, the liners ejected in. short intervals from the vacuum deep-drawing apparatusl can be coated in continuous operation with the thermosctting plastic and can then be stored and allowed to cure without delaying manufacture.

The tublike hollow liner deep-drawn from synthetic thermoplastic material is spraycoated with a uid polyester resin' composition. l`hen awoven fabric of glass bers isy applied to the coating under pressure and sprayed with another layer of polyester resin. Air en to each other may be used.

i is in the form of a shower tray] t coated with two outer layers 2 of thermosetting polyester resin. Aglass fiber fabric 3 is applied to the thermosetu'ng material while the same is still soft and is pressed into the plastics material untilit is embedded in it.

v The invention is not restricted to the above-mentioned synthetic thermoplastics and thermosetting materials but any combination of synthetic thermoplastic material and thermosetting plastics which are capable of being bonded I claim: 1. A plumbing fixture. capable of withstanding elevated temperatures during use', dening an open-topped cavity comprising: I t (a) an inner layer'of acrylic synthetic thermoplastic resin materialjsubstantially coextensive .with and eitt posed'insaid cavityjand 4(b) a spray-coating essentially' consisting of a cured thermosetting polyester plastic and glass libera embeddedin said plastic, (l) said coating covering said inner layer and being bonded thereto; and (2) .saidcodting providing'suppon to said f inner layer sucient ro 'retaim atelevated temperattures,A the strength of plumbing yxturejand the' ability of said plumbing fixture. to withsznd deforrmiimi.` [2. 'A plumbing fixture as set forth in claim 1, which is inthe form of'a wash-basin] [3. A plumbing lixturefas set forth in is in the form of a bath-tubt] [4.- A plumbing fixture as set forth claim 1, which in 'asini-,1, einen s. A plumbing fixture as ser forth in claim 1, tnwnich said synthetic thermoplastic .material essentially ,consists [6. A plumbing fixture asset forth in claim l, in 'which vsait! thermosetting plastic'is an unsaturated polyesten] t 7. vA plumbingiixture as set forth in claim L 'injwhich said coating comprises a plurality of layers of said thermosetting plastic, said bers being-embedded in of said 1ayers,and the other layerbeiiig substantiallyfree 8. A process of manufacturing a plumbing iixtnre that is capable of withstanding elevated temperatures use, which comprises:

(a) shaping acrylic synthetic thermoplasticfsheeting into a hollow body defining anopen-topped'- cavity therein; J-

(b) [applying to] sprayfcoaring `th'e outer surfaceof said body with a fluid coating composition including a thermosetting polyester plastic; (c) embedding reinforcing glass lbers in said-coating;

(d) curing said coating to provide 'support to said body suciiit to retain, at elevated tempei'atures, the strength of said plumbing xturc and-the ability of said plumbing xiure towithstand deformation.'

9. A process as set fortuin claim 8, in which vsaid sheeting is shaped by .vacuum deep drawing.

10. A process as set forth in claim 8, in which said acting essentially consists of polymethacrylate [11. A process asset forth in claim 8, in which said :rmosetting plastic essentially: consists of unsaturated lyesten] y s 1 l 12. A process as set forth in claim 8, in which said coatg is applied in a pluralitylof layers.

13. A process of manufacturing a shaped article from istie, which comprises vacuum-forming' acrylic syn- :tic thermoplastic sheeting to forma self-supporting dy defining an open-topped cavity therein, spraying :rmosettng -polyester plastic material on the outer sur- :e of said body to form a coating thereon, embedding nfor'cing glass fibers in said coating, and curing said :rmosetting plastic material.

14. A process as set forth in claim I3, in which 'said zthetic thermoplastic sheeting is polymethacrylate.

l5. A plumbing fixture, capable f withstanding elered temperatures during use, defining an opentopped ity comprising:

(a) a self-supporting vacuum deep-drawn inner layer of polymethacrylate synthetic thermoplastic resin sheeting substantially coextensive with and exposed in said cavity; and

(b) a spray-coating essentially consisting of a cured thermosetting unsaturated polyester plastic and glass #bers embedded in said plastic,

(1)-said coating covering said inner layer and being bonded thereto; and

(2) said coating providing support to said inner layer sufficient to retain, at elevated temperatures, the strength of said plumbing fixture and the ability of' said plumbing fixture to withstand deformation.

l'6. A process of manufacturing a plumbing fixture that capable of withstanding elevated temperatures during r, which comprises: (a) vacuum deep drawing polymethacrylate synthetic thermoplastic sheeting into a self-supporting hollow body dening an open-topped cavity therein; (b) ,removi deep drawing; y (c) spray-coating the outersurface of said body with a fluid coating composition' including unsaturated polyester plastic;

and

ng'the'body from the' means for vacuum a' thermosetting said plumbing xturet to withstand deformation, saidA j hollow body being self-supporting during curing. I7. A process of manufacturing a shaped article from plastic, which comprises vacuum-forming acrylic synthetic thermoplastic sheeting to form a self-supporting body dening an open-topped cavity therein, removing the selfsupportingl body from the vacuum forming means, spraying thermosetting unsaturatedv polyester plasticjnaterial 'an the outer surface of said body to form a coatingtthereon, embedding reinforcing glass fibers in said coating, and

[d)'errtb'edding reinforcing glass fbersrin said coating;

curing said thermosetting unsaturated polyester plastic material whereby the reinforced coating is to thel sel f-supporting body, said bqdy being self-supporting' durmg curing. v

18. An accelerated process of manufacturing shaped articles from plastic, which comprises:

(a) in a quick manner shaping by vacuumdorming means acrylic synthetic thermoplastic sheeting to farm a self-supporting body defining an open-topped cavity therein; and

(b) in a continuous operation so as not to delay manufacture, remjotving the body from the 1rtzvcutontfor'm ing means to allow a higherproductt'loltrt rate therefrom; thereafterspraying thermosetting unsaturated polyester plastic material on the outer surface of ,said lbody to form a coating thereon; embedding .reinforcing glass fibers in said coating; and curing said reinforced coatingwhile the body is being stored and self-supporting.A I

y vReferencesvCited l The following references, cited by .the Examiner, are

of record in the patented file of this patent or the original 

